Clothes dryer maintenance safety reminder system

ABSTRACT

A clothes dryer including a cabinet, a drum rotatably mounted in the cabinet, ductwork connected to the drum for circulating air, a heating element for providing heat to the drum, and a control system for operating the clothes dryer. The control system includes a warning indicator and a control module. The control module monitors and tracks usage of the clothes dryer. The warning indicator provides first and second warnings to a user based on the usage. The first warning indicates that factory authorized service is required to clean inside the cabinet of the clothes dryer, and the second warning indicates that the heating element has been disabled until the factory authorized service occurs. Preferably, the control module is further operative to completely disable the clothes dryer based on the usage.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/303,897, filed Mar. 4, 2016, which is incorporated herein byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject disclosure relates to safety mechanisms for clothes dryers,and more particularly to clothes dryer safety mechanisms that disablethe heating element or operation when maintenance is overdue by apredetermined amount of cycles and/or runtime.

2. Background of the Related Art

Clothes dryer fires are common events, which often result in loss ofproperty and endanger life. Typically, not only the vents and ductworkbut everywhere inside the cabinet becomes clogged with lint. Forexample, factors such as design, installation, use and maintenance canresult in lint accumulation near the heat sources such as the electricheating element and gas burners. Lint is an excellent fuel for fire sothat when left in proximity to the heating element, fires often occur.External vents are typically fairly easy to clean with easy access andno required tools. However, the interior of the dryer is difficult toaccess without proper tools, training and strength to move the clothesdryer. Due to the close proximity to the heating element, it is theinterior lint that is most likely to ignite. Further, cleaning of theinterior may void the clothes dryer warranty if not performed by anauthorized factory service representative, which is costly. As a result,the interior simply is not properly cleaned, if at all.

Several attempts have been made to address clothes dryer fires. Forexample, U.S. Pat. No. 4,622,759 to Abe et al. issued on Nov. 18, 1986discloses a clothes dryer with sensors and a control system thatmonitors temperature. Based on the sensors, power to heater may be shutoff. In short, if the clothes dryer runs too hot, the heater is shutoff.

U.S. PGPUB. No. 2002/0184786 to Miller, II published on Dec. 12, 2002discloses that dryer vent fires are a common hazard. When a fire isdetected, the power to the dryer is disconnected and an extinguishingagent is applied to the area.

SUMMARY OF THE INVENTION

In view of the above, a need exists for a system that insures propermaintenance of clothes dryers to prevent fires and the associateddamage.

The present disclosure is directed to a safety device for clothes dryersto prevent fires related to lint accumulation in hard to access placeslike inside the cabinet and ductwork. The additional components maysimply be a small printed circuit board that operates to turn on one ormore warning lights on the control panel of the clothes dryer afterrunning a certain number of cycles. When the dryer is safe, the warninglights will be green or off. When the first warning comes up, thewarning light turns yellow and may blink. The warning light signals thatthe dryer has to be professionally cleaned where the lint gathers at therear of the drum, inside the cabinet, in the internal ductwork and/orother typical collection areas. After the yellow light goes on, thewarning light turns red after another predetermined number of cycles.When the warning light turns red, the heating source becomes inoperableuntil the dryer is serviced and cleaned, at which time, the warninglight is reset. Until servicing, the clothes dryer will still operatewithout heat, preventing lint fires by disconnecting the heat source.The lack of heat will still tumble dry the clothing but the poorperformance will prompt the user to service their dryer.

In another embodiment, the subject technology is a clothes dryerincluding a cabinet, a drum rotatably mounted in the cabinet, ductworkconnected to the drum for circulating air, a heating element forproviding heat to the drum, and a control system for operating theclothes dryer. The control system includes a warning indicator and acontrol module. The control module monitors and tracks usage of theclothes dryer. The warning indicator provides first and second warningsto a user based on the usage. The first warning indicates that factoryauthorized service is required to clean inside the cabinet of theclothes dryer, and the second warning indicates that the heating elementhas been disabled until the factory authorized service occurs.Preferably, the control module is further operative to completelydisable the clothes dryer based on the usage.

And yet another embodiment of the present disclosure includes a safetysystem for a clothes dryer with a specialized printed circuit boardincluding memory storing an instruction set and data related to theclothes dryer and a first cycle count, and a processor in communicationwith the memory for running the instruction set. The processor isoperative to monitor and track cycles of the clothes dryer, compare thecycles to the first cycle count to determine if the cycles is greaterthan the first cycle count, and provide a first warning signal to a userwhen the cycles is greater than the first cycle count, wherein the firstwarning signal indicates factory authorized service is required to cleaninside a cabinet of the clothes dryer. Cleaning inside the cabinetincludes cleaning ductwork and/or an area around a rotating drum. Thememory may store a second cycle count so that the processor can comparethe cycles to the second cycle count to determine if the usage total isgreater than the second cycle count, and disable a heating element ofthe clothes dryer when the usage total is greater than the second cyclecount. The memory may also store a third cycle count so that theprocessor can compare the cycles to the third cycle count to determineif the usage total is greater than the third cycle count, and disablethe clothes dryer entirely when the usage total is greater than thethird cycle count. In one version, the safety system includes aheating-element-on indicator light and a service required light, thelights being in communication with the processor so that the firstwarning signal turns the heating-element-on indicator light from greento yellow and the service required light illuminates when the clothesdryer is disabled entirely.

Still another embodiment of the present disclosure includes a safetysystem for an appliance to monitor and track real time usage forproviding warnings and controlling operation including a specializedprinted circuit board having memory storing an instruction set and datarelated to the appliance, a first predefined criteria, and a secondpredefined criteria, and a processor in communication with the memoryfor running the instruction set. The processor can monitor and trackusage of the appliance to record a usage total, compare the usage totalto the first predefined criteria to determine if the usage total isgreater than the first predefined criteria, provide a first warningsignal to a user when the usage total is greater than the firstpredefined criteria, when the usage total is greater than the firstpredefined criteria, compare the usage total to the second predefinedcriteria to determine if the usage total is greater than the secondpredefined criteria, and disable a function of the appliance when theusage total is greater than the second predefined criteria. Theappliance may be a clothes dryer, first criteria is a first number ofcycles, the second criteria is a second number of cycles, and thefunction is providing heat from a heating element of the clothes dryer.A LED may be in communication with the processor, wherein the LED isgreen during normal operation, yellow as a result of the first warningsignal, and red when the function is disabled. The first warning couldalso be a text message sent to a manufacturer and/or an owner of theappliance. The processor may also send a message to an agent of amanufacturer of the appliance based upon the function being disabled.

It should be appreciated that the subject technology can be implementedand utilized in numerous ways, including without limitation as aprocess, an apparatus, a system, a device, a method for applications nowknown and later developed or a computer readable medium. These and otherunique features of the system disclosed herein will become more readilyapparent from the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those having ordinary skill in the art to which the disclosedtechnology appertains will more readily understand how to make and usethe same, reference may be had to the following drawings.

FIG. 1 is a perspective view of a clothes dryer with the housingpartially cutaway to illustrate interior components in accordance withthe subject technology.

FIG. 2 is a block diagram of a safety mechanism implemented inaccordance with the subject technology.

FIG. 3 is a flowchart depicting a process for operating a clothes dryerutilizing a safety process in accordance with the subject technology.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The subject technology overcomes many of the prior art problemsassociated with hazardous conditions in clothes dryers. The advantages,and other features of the technology disclosed herein, will become morereadily apparent to those having ordinary skill in the art from thefollowing detailed description of certain preferred embodiments taken inconjunction with the drawings which set forth representative embodimentsof the present technology and wherein like reference numerals identifysimilar structural elements.

In brief overview, the subject technology relates to appliance safetysuch as clothes dryer safety mechanisms that disable the appliance(e.g., disabling a heating element) or operation when maintenance isoverdue by predetermined criteria (e.g., an amount of cycles and/orruntime).

Referring now to the FIG. 1, there is shown a clothes dryer 100 inaccordance with the subject disclosure. The clothes dryer 100 includes acabinet 102, which is shown in partial cutaway to illustrate interiorcomponents. A control panel 104 mounts on the cabinet 102 to allow usersto selectively program operation of the clothes dryer 100. The controlpanel 104 may have a selector dial, a plurality of selector buttons,switches and the like (not explicitly shown) as necessary to accomplishoperation in accordance with the subject technology. A LED display 106also mounts on the housing to provide visual indication to users of thestatus of the clothes dryer. In one embodiment, the LED display 106includes three LEDs 118 a-c to provide easy review of the status of theclothes dryer 100. Commonly, the clothes dryer 100 also includes a startbutton 108 that is used to begin a drying cycle.

A drum 110 is mounted for rotational movement in the cabinet 102. Onceclothes are placed in the drum 110 and a dry cycle is started, a heatingelement 112 raises the temperature inside the drum 110 to facilitatedrying of the clothes. The clothes are placed and secured in the drumthrough a latching door mechanism (not shown). The heating element 112may use electricity or natural gas to generate the heat. Ductwork 114allows air to circulate through the drum 110. Typically, the circulatingair is driven through the clothes dryer 100 by an air handling unit 116.As noted above, lint may collect inside the cabinet 102 and in theductwork 114. By the lint being in close proximity to the heatingelement 112, a fire hazard exists. Operation of the clothes dryer 100 iscontrolled by a control module 200 (see FIG. 2).

Still referring to FIG. 1, various information (not shown) issilkscreened onto the cabinet so that users inherently understand themeaning of the LEDs 118 a-c. For example, LED 118 a has the words “LINTFILTER” adjacent thereto and is typically off. A lint filter sensor (notshown) provides a signal to a control module 200 so that when cleaningof the lint filter is required, the LED 118 a illuminates, preferably ina red color.

The LED 118B has the word “HEAT” adjacent thereto and is typicallyilluminated green. However, when service such as cleaning of the cabinet102 and ductwork 114 is required, the LED 118 b turns from green toyellow to provide indication of the required service. The LED 118 b mayalso blink to further draw the users attention thereto. Once thecriteria to disable the heating element 112 is reached, the LED 118 bturns from yellow to red. Again, the LED 118 b may blink to drawattention thereto as the criteria for disabling the clothes dryer 100completely approaches.

The LED 118 c has the words “SERVICE REQUIRED” adjacent thereto and istypically off. However, when service by a factory technician becomes sooverdue that operation of the clothes dryer 100 will be disabled, theLED 118 c illuminates red and blinks to further draw the users attentionthereto. Once the factory technician has performed the requiredmaintenance, the LEDs 118 a-c are reset. More particularly detail of theoperation of the clothes dryer 100 is described below. The LED display106 may alternatively be an LCD screen that provides messages, variousimages and the like to enhance operation of the clothes dryer 100 inaccordance with the subject technology.

Referring now to FIG. 2, a somewhat schematic block diagram of thecontrol module 200 is shown. The control module 200 includes one or moredigital data processing devices particularly suited to work in variousembodiments of the subject technology. The control module 200 alsointeracts with the control panel 104, the LED display 106, and the startbutton 108. Typically, the control module 200 is a specialized printedcircuit board with components for receiving, processing, displaying,and/or transmitting digital and/or analog data. Although shown as adiscrete singular element, the control module 200 may have separatecomponents distributed throughout the clothes dryer 100.

The control module 200 includes a processor 220, which is generallylogic circuitry that responds to and processes instructions. Theprocessor 220 can include, without limitation, a central processingunit, an arithmetic logic unit, an application specific integratedcircuit, a task engine, and/or any combinations, arrangements, ormultiples thereof. The processor 220 is in communication with memory222. Typical memory 222 includes random access memory (RAM), rewritableflash memory, read only memory (ROM), mechanisms and structures forperforming I/O operations, and a storage medium such as a magnetic harddisk drive(s). The memory 222 may be a combination of integral andexternal memory. The memory 222 includes software 224 and a plurality ofmodules 226, 228, 230 as needed to perform the functions of the subjecttechnology.

For example, the software 224 may include an operating system forexecution on the processor 220. Software or code generally refers tocomputer instructions which, when executed on one or more digital dataprocessing devices, cause interactions with operating parameters,sequence data/parameters, database entries, network connectionparameters/data, variables, constants, software libraries, and/or anyother elements needed for the proper execution of the instructions,within an execution environment in memory. A module is a functionalaspect, which may include software and/or hardware. Typically, a moduleencompasses the necessary components to accomplish a task. It isenvisioned that the same hardware (e.g., memory and processor) couldimplement a plurality of modules and portions of such hardware beingavailable as needed to accomplish the task.

For example, a database module 226 creates, stores, and maintains dataand multiple databases necessary for the proper operation of the subjecttechnology. A program module 228 stores an instruction set to allow theoperator to program operation of the control module 200 and, in turn,the operation of the clothes dryer 100 by using the control panel 104.An algorithm module 230 stores an instruction set to allow the processorto apply one or more algorithms for operation of the clothes dryer 100.

The control module 200 also includes various other circuitry 236 (notdrawn distinctly) as needed for proper operation. For example, thecircuitry 236 may include a power module, control circuitry, circuitryfor processing logical operations, integral A/D conversion circuitry, anintegral display driver, a peripheral eeprom (non-volatile rewriteablememory for storing user settings and the like), an external flash memorychip (for in-field software updates), and an external WIFI radio whichincludes built-in IP stack and WIFI encryption functionality.

Still referring to FIG. 2, the control module 200 also includes a WiFimodule 238 and/or wired communication channels 240 to facilitatecommunication with external devices such as a cellular telephone, homenetwork, other devices and the like. The control module 200 also has aconnector sections 204 for interacting with the other components such asthe drum 110, heating element 112, and air handling unit 116. Althoughdrawn as part of the processor 220, the WiFi module 238 may be separateor otherwise incorporated into the clothes dryer 100.

Those of ordinary skill will recognize that the hardware, software,modules, sensors, elements, devices and various processes discussedherein are merely exemplary of the functionality performed by thedisclosed technology and thus such hardware and processes (and/or theirequivalents) may be implemented in commercial embodiments in variouscombinations without materially affecting the operation of the disclosedtechnology. It is also envisioned that the control module 200 mayinteract with a comprehensive home/site controller that controls theoperation of additional systems (e.g., air conditioning) along withadditional components and sensors (e.g., smoke detectors etc.) and thelike.

The following flow charts herein illustrate the structure or the logicof the present technology, possibly as embodied in program software forexecution on the processor 220 of the control module 200. Those skilledin the art will appreciate that the flow charts illustrate thestructures of the program software or code elements, which may includelogic circuits on an integrated circuit and/or printed circuit board,that function according to the present technology. As such, the presenttechnology may be practiced by a specialized machine component thatrenders the program software in a form that instructs a processor toperform a sequence of function steps corresponding to those shown in theflow charts and equivalents.

Referring now to FIG. 3, there is illustrated a flowchart depicting aprocess 300 for preventing normal operation of the clothes dryer 100when maintenance such as cleaning the cabinet 102 for lint is overdue inaccordance with the subject technology. Initially, the process 300begins under ongoing operation circumstances as opposed to an initialstart-up condition when power is applied to the clothes dryer. At step302, the process 300 begins by initiating the main program functionloop.

At step 304, the process 300 sets up the internals for the processor 220such as initiating the registers and the like. At steps 306 and 308, thenecessary data is loaded from the memory 222. Such data may includepre-defined criteria for when to provide indication (i.e., warning) tothe user and when to take further action such as disabling the heatingelement 112. Such criteria are programmed into the memory 222 and keptin non-volatile memory storage.

At step 310, the main programming loop is entered. In step 312, aninterrupt is driven by an internal timer so that a live variable isupdated. The live variable is the elapsed (live) time. At step 314, theprocess 300 checks the inputs to determine if a service switch change isrequired. For example, the processor 220 can compare a number of cyclesof use of the clothes dryer 100 against a predetermined criteria so thatwhen the number of cycles exceeds the predetermined criteria, anindication of service being recommended is provided. As noted above, theprocessor 220 changes the state of the LED 118 b from green to yellow toindicate that service is required.

At step 316, the process 300 prepares to save the updated data bycollecting a snapshot of all the relevant data. At step 318, therelevant data is loaded into temporary registers as the active registerscontinue to update. The relevant data is then loaded into non-volatileRAM memory at step 320.

Still referring to FIG. 3, at step 322, the process 300 evaluates therelevant data to determine if any of the limits have been exceeded.Based upon the evaluation of the relevant data, the processor 220 takescontrol action (e.g., disabling the heating element 112) and change ofstate for the LEDs 118 a-c as needed at step 324. Once the user has beenwarned and/or the necessary protection against hazard has beenaccomplished, the process 300 proceeds to step 330. At step 330, theprocess 300 checks to see if the clothes dryer 100 is running or in anidle state. If in an idle state, the control module 200 can enter anidle state as well, preferably a sleep mode to conserve power. Theprocess 300 will loop through steps 310-330 to insure that the user isprotected and hazards are avoided.

Optionally, the factory technician or other user may utilize diagnosticfunctions in the process 300 at steps 326-328. At step 326, the process300 can display a visual of the run time, cycles, maintenance historyand the like. The technician may have to utilize a diagnostic tool toaccess the reading or use the LED display 106. At step 328, the process300 can calculate the run time and otherwise tabulate relevantmaintenance data for presentation at step 326.

As can be seen from review of the above, the subject technology providesa safety device for clothes dryers to prevent fires related to lintaccumulation in hard to access places like inside the cabinet andductwork. The additional components may simply be a small printed.circuit board and warning light(s). The warning lights not only providewarnings to the consumer but indicate various states of operation basedupon run-time or other usage. The states of operation can includeoperation without heat, completely disabled and the like.

In one embodiment, the predefined criteria can be an amount of calendartime such as 18 months. As such, an 18 month interval without servicingcan start a grace period (e.g., 6 months) of still normal operation inwhich a single warning light is yellow. At the end of the grace period,the heating element is disabled and the warning light turns red. Thedisabled heating element period can also be set to a temporal limit suchas another 6 months. As the end of the disabled heating element periodapproaches, the warning light blinks to indicate that the clothes dryerwill become completely disabled soon unless proper service is performed.Once the disabled heating element period ends without service, theclothes dryer is disabled and can only be reset by a technician, whowould need to clean the clothes dryer and reset the warning system.Preferably, the disabling of the clothes dryer may be a general overalldisablement or a locking of the door.

In one embodiment, the criteria is a number of cycles. A cycle could bedefined as simply starting a drying cycle, 1 hour of run-time, andvariations thereof. Preferably, when a cycle is a full drying cycle, thecaution yellow LED is illuminated after a criteria selected from 416,520 or 624 cycles. After another 50 cycles, the red LED illuminates withthe clothes dryer still cycling but disabling of the heating element112. Blinking could occur for 5 cycles as transition between the periodsapproaches. For another example, the clothes dryer could modifyoperation and provide warning based on usage recorded in an hour-meteroff the hours of operation of the heating element, rotation of the drum,and/or running of the air handling unit. Such run-time could also beconverted into cycles such as by equating 1 hour of operation beingcounted as 1 cycle. Additionally, the WiFi module can email the samewarnings and relevant status information to the manufacturer or aservice provider, who can in turn contact homeowner to schedule aservice appointment when the product has been registered.

Although the subject technology has been described with respect toclothes dryers, it is envisioned that the subject technology would beequally applicable to other fields and applications such as onrefrigerator icemakers, dishwashers, water treatment systems such asreverse osmosis filters and UV light sanitizing modules, stovetop ventsor any appliance that may need periodic maintenance such as filterchanging or cleaning. The subject technology can also be formed as aretrofit kit for use on existing appliances such as clothes dryers.

It will be appreciated by those of ordinary skill in the pertinent artthat the functions of several elements may, in alternative embodiments,be carried out by fewer elements, or a single element. Similarly, insome embodiments, any functional element may perform fewer, ordifferent, operations than those described with respect to theillustrated embodiment. Also, functional elements (e.g., modules,processors, memory, printed circuit boards, light emitting diodes,databases, interfaces and the like) shown as distinct for purposes ofillustration may be incorporated within other functional elements in aparticular implementation.

All patents, patent applications and other references disclosed hereinare hereby expressly incorporated in their entireties by reference.While the subject technology has been described with respect topreferred embodiments, those skilled in the art will readily appreciatethat various changes and/or modifications can be made to the subjecttechnology without departing from the spirit or scope of the inventionas defined by the appended claims. For example, each claim may dependfrom any or all claims in a multiple dependent manner even though suchhas not been originally claimed.

What is claimed is:
 1. A clothes dryer comprising: a cabinet; a drumrotatably mounted in the cabinet; ductwork connected to the drum forcirculating air; a heating element for providing heat to the drum; and acontrol system for operating the clothes dryer, the control systemincluding: a warning indicator; and a control module for: monitoring andtracking usage of the clothes dryer; using the warning indicator toprovide first and second warnings to a user based on the usage, whereinthe first warning indicates that factory authorized service is requiredto clean inside the cabinet of the clothes dryer, and the second warningindicates that the heating element has been disabled until the factoryauthorized service occurs.
 2. A clothes dryer as recited in claim 1,wherein the control module is further operative to completely disablethe clothes dryer based on the usage.
 3. A safety system for a clothesdryer comprising: a specialized printed circuit board including: memorystoring an instruction set and data related to the clothes dryer and afirst cycle count; and a processor in communication with the memory forrunning the instruction set, wherein the processor is operative to:monitor and track cycles of the clothes dryer; compare the cycles to thefirst cycle count to determine if the cycles is greater than the firstcycle count; and provide a first warning signal to a user when thecycles is greater than the first cycle count, wherein the first warningsignal indicates factory authorized service is required to clean insidea cabinet of the clothes dryer.
 4. A safety system as recited in claim3, wherein cleaning inside the cabinet includes cleaning ductwork and anarea around a rotating drum.
 5. A safety system as recited in claim 3,wherein: the memory stores a second cycle count; and the processor isfurther operative to: compare the cycles to the second cycle count todetermine if the usage total is greater than the second cycle count; anddisable a heating element of the clothes dryer when the usage total isgreater than the second cycle count.
 6. A safety system as recited inclaim 5, wherein: the memory stores a third cycle count; and theprocessor is further operative to: compare the cycles to the third cyclecount to determine if the usage total is greater than the third cyclecount; and disable the clothes dryer entirely when the usage total isgreater than the third cycle count.
 7. A safety system as recited inclaim 6, further comprising a heating-element-on indicator light and aservice required light, the lights being in communication with theprocessor so that the first warning signal turns the heating-element-onindicator light from green to yellow and the service required lightilluminates when the clothes dryer is disabled entirely.
 8. A safetysystem for an appliance to monitor and track real time usage forproviding warnings and controlling operation comprising: a specializedprinted circuit board including: memory storing an instruction set anddata related to the appliance, a first predefined criteria, and a secondpredefined criteria; and a processor in communication with the memoryfor running the instruction set, wherein the processor is operative to:monitor and track usage of the appliance to record a usage total;compare the usage total to the first predefined criteria to determine ifthe usage total is greater than the first predefined criteria; provide afirst warning signal to a user when the usage total is greater than thefirst predefined criteria; when the usage total is greater than thefirst predefined criteria, compare the usage total to the secondpredefined criteria to determine if the usage total is greater than thesecond predefined criteria; and disable a function of the appliance whenthe usage total is greater than the second predefined criteria.
 9. Asafety system as recited in claim 8, wherein the appliance is a clothesdryer, first criteria is a first number of cycles, the second criteriais a second number of cycles, and the function is providing heat from aheating element of the clothes dryer.
 10. A safety system as recited inclaim 8, further comprising a LED in communication with the processor,wherein the LED is green during normal operation, yellow as a result ofthe first warning signal, and red when the function is disabled.
 11. Asafety system as recited in claim 8, wherein the first warning is a textmessage.
 12. A safety system as recited in claim 8, wherein theprocessor is further operative to send a message to an agent of amanufacturer of the appliance based upon the function being disabled.